Significant R&D achievements
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In keeping with the R&D strategy adopted by the Group, research projects implemented in 2015 focused on:
1. Improving product quality,
2. Streamlining the operation of selected production lines,
3. Developing innovative product technologies.
Most R&D projects consisted in continuation or extension of work started in previous years. In implementing those projects, the Parent closely cooperated with a number of universities and scientific institutions.
The most important R&D initiatives in 2015 included:
- Enhancement of the fertilizer manufacturing process through appropriate selection of inorganic additives and anti-caking agents,
- Comprehensive assessment of the effectiveness and benefits of a new fertilizer with reduced sulfur content − Saletrosan® 30 makro in the case of selected crops,
- Development of new varieties of modified plastics, with the use of various additives enabling specialist application of the plastics,
- A series of research projects designed to reduce caprolactam manufacturing costs and further improve the product quality through optimised operation of selected process units,
- Development of new product technologies,
- Feasibility studies into the possibility of entering new areas of business,
- Launch of a project to develop technologies for decomposition of waste sodium sulfate solutions into sulfuric acid and soda lye. The project is co-financed by the National Centre for Research and Development, and implemented in cooperation with the New Chemical Syntheses Institute, the Inorganic Chemistry Branch (‘IChN’) in Gliwice.
Grupa Azoty KĘDZIERZYN
In 2015, R&D activities at Grupa Azoty KĘDZIERZYN focused on:
- Identifying new products to expand the Company’s product portfolio,
- Implementing technical and technological upgrades to reduce energy intensity of the manufacturing processes for key intermediate products.
The most important R&D initiatives included:
- In the OXOPLAST Business Unit: R&D initiatives focused on new types of non-phthalate plasticizers and potential non-alcohol products of butyraldehyde processing (intermediate product of oxo synthesis). Grupa Azoty KĘDZIERZYN completed the start-up of a new unit for continuous production of Oxoviflex®, with an annual capacity of 50 thousand tonnes. It also continued research activities geared towards expanding the offering of non-phthalate plasticizers, including bio-based plasticizers.
- In the area of fertilizer production: continued work on new compound fertilizers. A new UAN liquid fertilizer plant with an annual capacity of 100 thousand tonnes was launched. Work is also in progress on new fertilizer formulas, including fertilizers with higher magnesium content.
- At the same time, the company worked on solutions aimed at reducing energy consumption in the manufacturing of key intermediate products (primarily ammonia). Ammonia synthesis unit was upgraded through the replacement of the converter’s interior, thereby reducing pressure of the synthesis process. Work is underway to increase output of the TKV nitric acid production unit. The technological upgrades are also expected to improve technological reliability of manufacturing processes for key intermediate products used in fertilizer production.
Grupa Azoty POLICE
At Grupa Azoty POLICE, R&D projects are both driven by the company’s internal needs and forced by the market reality.
In 2015, R&D work undertaken by Grupa Azoty POLICE focused primarily on:
- Conducting laboratory research and quarter-technical analyses,
- Preparing feasibility studies, expert reports and analyses.
These activities were conducted in partnership with third-party institutions in Poland and abroad.
In addition to launching new research initiatives, in 2015 the company continued its projects commenced in 2014. The following is a list of major completed R&D projects at Grupa Azoty POLICE:
- Feasibility study on the upgrade of the post-hydrolytic sulfuric acid concentration unit,
- Research into the possibility of recovering phosphorous from the phosphogypsum landfill site leachate,
- Research into the possible improvement of quality of phosphoric acid,
- Analysis of the environmental assessment of fertilizers’ lifespan,
- Research into a new liquid fertilizer to be produced based on urea and ammonia sulfate derived from post-crystallization acid, and assessment of its marketability,
- Research into the possible application of a new type of titanium white to be used in plastics,
- Analysis of the possibility of producing NOXy solution directly from urea solution discharged from the synthesis unit.
Grupa Azoty PUŁAWY
In 2015, key R&D initiatives undertaken at Grupa Azoty PUŁAWY focused on:
- Developing new and enhancing existing technologies,
- Improving the company’s products.
To a large extent, R&D work involved the continuation or extension of the initiatives commenced in previous reporting periods.
Key R&D projects included:
- Further elaboration of the concept for implementation of a process for mechanical granulation of ammonium nitrate fertilizers,
- Research into an NOx emissions reduction technology involving the use of urea solution, and analysis of the feasibility of its application,
- Development and implementation of a treatment procedure for biological wastewater treatment plant’s sludge with a view to meeting future legal requirements in this respect;
- Development of a synthesis technology for biodegradable plastics based on semi-finished and finished products manufactured at Grupa Azoty PUŁAWY and its subsidiaries,
- Feasibility studies and design work to improve efficiency of key manufacturing processes.
Research into optimisation of efficiency of the existing and contemplated fertilizer products of Grupa Azoty PUŁAWY.
In 2015, the company commenced implementation of the project “Support for low-emission agriculture able to adapt to climate change now and within the 2030 and 2050 timeframes (LCAgri)”, co-financed by the National Centre for Research and Development, which aims at improving efficient resource utilisation by implementing innovative low-carbon agricultural solutions and promoting sustainable application of mineral fertilizers at Polish farms throughout the fertilizer products lifespan, based on the LCA method.
The project is carried out by a consortium of Grupa Azoty PUŁAWY and the following entities:
- Institute of Soil Science and Plant Cultivation – State Research Institute – Project Coordinator,
- Agrophysical Institute – Polish Academy of Sciences,
- Environmental Protection Institute – State Research Institute.
